Charging fault?

Hi Org, hope you can help

After reading loads of posts incluing the entire epic nadine thread I decided to see if I could fix my ailing 01 sv650 myself.

I bought the bike about 18months ago, everything was fine until it stopped starting on me.
I brought the bike to a bike shop and the guy said that my battery was gone and that he replaced the reg/rec with a working used one he had.
My bike was generally good after that but remained a bit tempermental about charging, i put this down to my frequent short trips so bought a trickle charger and thought no more of it.

Anyway about 8 weeks ago my trickle charger stopped working and soo after that my bike stopped wanting to start (battery flat)

I was due a service anyway so too the bike to the shop and the guy said he checked the bike over and replaced the battery as it was gone.


Less than two weeks later the bike again did not want to start so I took it back to the shop and the guy said he did all the diagnostics he could and it checked out fine, he charged the battery and i was on my way.

Now my bike again has a flat battery, I got hold of another trickle charger and currently have the battery on charge,
Being ****ed off I decided to have a look ath the electrics myself (no idea what i was looking for)

Here is a pic of what I discovered



Here is where I show my ignorance of electrics, see the radiator looka like on the left and the yellow wires that come out the bottom of it, well they terminate in a plug in the bottom right of the picture, these wires are corroded and broken

Close Up


There is also sign of plastic meting on this plug


How did the mechanic miss this??? Can I fix this my self cause I am a broke student?

Also of note is that my wiring seems differnt to other pics I have seen
That plug with the corroded wire has a an identical plug connected in series with it, from reading the manual I thing its called the generator coupler, While I had this exposed I performed the "generator coil reisistance inspection" as in the manual

Here are some pics










The results from the resistance test were
Bottom left and top: 0.9ohms
Bottom right and top: 0.7 ohms
Bottom two together: 0.8 ohms

please help!!!!!

I dont know if I have a bike thats screwed or a mechanic thats screwing me!!

it looks like he has fitted a rectifier from a different bike. they are all around about the same but the wire terminals are different.
if the contacts are not very good then they will burn out as yours did.
i would find a proper reg/rec and install that.
do you have an alarm fitted as some of them really take it out on the battery after just a couple of days.

thanks for the reply,
There was an alarm on the bike but it wasnt very good so it was removed.
The only other electrical mod was changed the buls tonightbreakers.
Is there anything I could do myself as an interim fix for the wiring as I dont have the cash for a new reg/rec right now.
Could i by pass the burnt out junction and just join the wires directly?

[fastdruid]

Remove those three blue crimps, (where it has melted and corroded), buy some decent crimp connectors, re-crimp them and reconnect.

Total cost should be less than £10 for a set of crimp pliers, decent crimps and some insulating tape.

Druid

[5hort5]

lmfao "guy said he did all the diagnostics he could", well clearly he doesn't know anything and should be put against a wall and shot.

I agree with Druid, reconnect it up properly and then test the voltage coming back of the black and red wires at idle and at 5k rpm and post the results.

cheers for the replies,
@5hort5, I was fairly ****ed off when I saw the state of the wiring, I very much doubt that its deteriorated by this much since he last 'say' so really dont like been taken advantage of.

By black and red wires I'm assuming this is done across the terminals of the battery?,
Will post back tomorrow with the results.
Cheers

[fastdruid]

The reg/rec is 'fed' by the three yellow wires and outputs via the red and black, I can't remember the figures off the top of my head but it should be something like 12.5v engine off, ign off. Then with engine on and running should rise to something like 13v going up to something like 14-15v when you rev it.

Druid

[5hort5]

Yer that's the way I do it but this could eb the wrong way lol. Anyway, when you are testing try it at idle, idle with lights on, 5k rpm, 5k rpm with lights on and report back the results.

loose electrical connection caused the burnout. If you make any changes to wiring colours make sure you make a drawing for yourself to remember if anything happens next time.

It would be great if it turns out to be such a simple fix!
Hopefully once I reconnect it there won't be another burnout for a while.
Won't be till after my college exams that I can afford a new ref/rec.
Is this something the mechanic should have spotted. Time to change shop?
Will post back tomorrow evening with an update
thanks guys